Methods for manufacturing a jaw assembly for an electrosurgical forceps

ABSTRACT

A method of assembling a jaw member of an electrosurgical forceps includes aligning in vertical registration an electrically conductive seal plate, an insulative spacer and a jaw support. The method further includes stacking the seal plate atop the insulative spacer and the jaw support such that a flange depending from the seal plate seats within a corresponding cavity defined within a flange depending from the insulative spacer which, in turn, seats within a cavity defined within the jaw support. The method further includes mechanically securing the seal plate, insulative spacer and jaw support to one another and securing a jaw housing to surround the jaw support, the insulative spacer and the seal plate.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 16/362,162, filed on Mar. 22, 2019, now U.S. Pat. No. 11,523,861.

FIELD

The present disclosure relates to electrosurgical instruments and, more particularly, to electrosurgical forceps for grasping, treating, and/or dividing tissue and methods for manufacturing the same.

BACKGROUND

A surgical forceps is a plier-like instrument which relies on mechanical action between its jaws to grasp tissue. Electrosurgical forceps utilize both mechanical clamping action and electrical energy to treat tissue, e.g., coagulate, cauterize, and/or seal tissue.

Typically, during assembly, an electrically conductive tissue sealing plate of each jaw member is mounted atop a jaw housing and is secured in place utilizing various manufacturing techniques.

SUMMARY

As used herein, the term “distal” refers to the portion that is being described which is further from a surgeon, while the term “proximal” refers to the portion that is being described which is closer to a surgeon. Further, to the extent consistent, any of the aspects described herein may be used in conjunction with any or all of the other aspects described herein.

As used herein, the terms parallel and perpendicular are understood to include relative configurations that are substantially parallel and substantially perpendicular up to about +/— 10 degrees from true parallel and true perpendicular.

Aspects according to the present invention include a method of assembling a jaw member of an electrosurgical forceps, including: aligning in vertical registration an electrically conductive seal plate, an insulative spacer and a jaw support; stacking the seal plate atop the insulative spacer and the jaw support such that a flange depending from the seal plate seats within a corresponding cavity defined within a flange depending from the insulative spacer which, in turn, seats within a cavity defined within the jaw support; mechanically securing the seal plate, insulative spacer and jaw support to one another; and securing a jaw housing to surround the jaw support, the insulative spacer and the seal plate (or at least a portion thereof).

In aspects according to the present disclosure, one or more rivets or screws mechanically secure the seal plate, insulative spacer and jaw support to one another. In other aspects, the method includes feeding an electrical connection from the seal plate, through the insulative spacer and jaw structure and back to an electrical source.

In aspects according to the present disclosure, the jaw housing is secured by overmolding the jaw housing to surround the jaw support, the insulative spacer and the seal plate. In yet other aspects, the seal plate includes a peripheral edge that mechanically engages a corresponding lip of the jaw housing to secure the jaw housing to the seal plate.

In aspects according to the present disclosure, the seal plate includes a peripheral edge that mechanically engages the jaw housing during the overnolding process to secure the jaw housing to the seal plate. In still other aspects, the jaw housing is made from an insulative material. Yet in other aspects, the jaw support is made from metal.

Aspects according to the present invention include a method of assembling a jaw member of an electrosurgical forceps, including: aligning in vertical registration an electrically conductive seal plate, an insulative spacer and a jaw support; seating the seal plate atop the insulative spacer and the jaw support such that a flange depending from the seal plate depends generally perpendicular to the seal plate and is spaced relative to the insulative spacer in an initial, pre-overmold configuration; and overmolding a jaw housing to surround the seal plate, insulative spacer and jaw support wherein the overmolding forces the flange of the seal plate to mechanically engage the insulative spacer in a second, after-overmold configuration.

In aspects according to the present disclosure, the depending flange surrounds the periphery of the seal plate. In other aspects, the depending flange mechanically engages the insulative spacer on either side thereof to secure the seal plate thereon.

In still other aspects, the jaw housing is made from an insulative material. Yet in other aspects, the jaw support is made from metal.

Aspects according to the present invention include a method of assembling a jaw member of an electrosurgical forceps, including: aligning an electrically conductive seal plate having a mesh-like material engaged to a bottom surface thereof and a jaw support, the mesh-like material spacing the seal plate and the jaw support relative to one another; overmolding a first material to fill the mesh-like material and secure the seal plate and the jaw support in spaced relation relative to one another; and overmolding a jaw housing to surround the seal plate, mesh-like material and jaw support.

In aspects according to the present disclosure, the mesh-like material is bonded, welded, integrally associated with or mechanically engaged to the seal plate. In other aspects, the jaw housing is made from an insulative material. Yet in other aspects, the jaw support is made from metal.

BRIEF DESCRIPTION OF THE DRAWINGS

Various aspects and features of the present disclosure are described hereinbelow with reference to the drawings wherein like numerals designate identical or corresponding elements in each of the several views:

FIG. 1A is a side, perspective view of an electrosurgical forceps provided in accordance with aspects of the present disclosure;

FIG. 1B is an enlarged, side, perspective view of a distal portion of the jaw member of FIG. 1A;

FIG. 2 is a schematic cross section of a jaw member in accordance with one aspect of the present disclosure showing a seal plate being deformed against a jaw spacer as part of a manufacturing technique for securing the seal plate atop the jaw member;

FIG. 3A is a schematic cross section of another jaw member in accordance with another aspect of the present disclosure showing a seal plate being held in place prior to an overmolding process;

FIG. 3B is a schematic cross section of the jaw member of FIG. 3A showing the seal plate secured in place after the overmolding process;

FIG. 4A is a schematic cross section of another jaw member in accordance with another aspect of the present disclosure showing a seal plate being held in place by a mesh-like material prior to an overmolding process;

FIG. 4B is a schematic cross section of the jaw member of FIG. 4A showing the seal plate secured in place after the overmolding process;

FIG. 5 is a schematic cross section of another jaw member in accordance with another aspect of the present disclosure showing a seal plate including a series of mechanical interfaces engaging a complementary series of mechanical interfaces of a jaw structure to secure the seal plate thereto;

FIG. 6A is an enlarged, side, perspective view of a distal portion of a jaw member in accordance with another aspect of the present disclosure showing a seal plate including a mechanical interface engaging a complementary mechanical interface of a jaw structure and a complementary mechanical interface of a spacer to secure the seal plate the jaw structure;

FIG. 6B is an exploded, perspective view of the jaw member of FIG. 6A; and

FIG. 6C is a side, perspective cross section of the jaw member of FIG. 6A with an insulative coating surrounding the jaw structure.

DETAILED DESCRIPTION

Referring generally to FIGS. 1A and 1B, a forceps 100 provided in accordance with the present disclosure includes first and second shaft members 110, 120 each having a proximal end portion 112 a, 122 a and a distal end portion 112 b, 122 b. Although the figures and the below description relate to an open forceps, the present disclosure is equally applicable to a laparoscopic forceps, however, the electrical and mechanical connections may differ depending upon a particular purpose.

An end effector assembly 200 of forceps 100 includes first and second jaw members 210, 220 extending from distal end portions 112 b, 122 b of shaft members 110, 120, respectively. Forceps 100 further includes a pivot member 130 pivotably coupling first and second shaft members 110, 120 with one another, a knife 140 (not shown), a knife deployment mechanism 150 for selectively deploying the knife relative to end effector assembly 200, a knife lockout 170 for inhibiting deployment of knife prior to sufficient closure of jaw members 210, 220, and a switch assembly 180 for enabling the selective supply of electrosurgical energy to end effector assembly 100. An electrosurgical cable 300 electrically couples forceps 100 to a source of energy (not shown), e.g., an electrosurgical generator, to enable the supply of electrosurgical energy to jaw members 210, 220 of end effector assembly 200 upon activation of switch assembly 180.

Continuing with reference to FIGS. 1A and 1B, each shaft member 110, 120 includes an outer housing 116, 126 surrounding at least a portion of the respective shaft members 110, 120 and a handle 118, 128 engaged with the respective outer housing 116, 126 towards proximal end portions 112 a, 122 a of shaft members 110, 120, respectively. Outer housings 116, 126 enclose and/or operably support the internal components disposed within shaft members 110, 120. More specifically, as detailed below, outer housing 116 of shaft member 110 encloses and supports at least knife deployment mechanism 150, and lockout 170, while outer housing 126 of shaft member 120 receives electrosurgical cable 300 and encloses and supports switch assembly 180, and the lead wires (not shown) of electrosurgical cable 300. Handles 118, 128 are engaged with outer housings 116, 126 towards proximal end portions 112 a, 112 b of shaft members 110, 120 and extend outwardly from shaft members 110, 120. Handles 118, 128 define finger holes 119, 129 configured to facilitate grasping and manipulating shaft members 110, 120.

Referring to FIG. 1B, jaw member 210 includes an electrically-conductive, tissue-contacting plate 214 that is secured atop a spacer 233 and a jaw support structure 235 surrounded by an insulative housing 216. Tissue-contacting plate 214 defines a longitudinally-extending knife channel 215 a extending at least partially therethrough and may include one or more stop members 215 b disposed thereon and electrically isolated therefrom. Insulative housing 216 of jaw member 210 is overmolded or otherwise secured about a portion of jaw support 212 and tissue-contacting plate 214 of shaft member 110. Other manufacturing techniques are explained in detail below with respect to FIGS. 2A-6C. An electrical lead 310 (see FIGS. 6A-6C) is configured to electrically couple to tissue-contacting plate 214 and insulative housing 216 is configured to protect and facilitate routing of the electrical lead 310 from shaft member 120, around pivot 130, and distally therefrom to electrically couple to tissue-contacting plate 214.

A distal portion 217 a of insulative housing 216 of jaw member 210 extends about the periphery of tissue-contacting plate 214 and defines a main section 218 a, a raised section 218 b, and a beak section 218 c. Main section 218 a of distal portion 217 a of insulative housing 216 extends on either side of tissue-contacting plate 214 and is offset relative thereto such that tissue-contacting plate 214 is raised relative to main section 218 a. Raised section 218 b of distal portion 217 a of insulative housing 216 extends distally from main section 218 a on either side of tissue-contacting plate 214 and is still recessed relative to tissue-contacting plate 214 but is closer to being co-planar with tissue-contacting plate 214 as compared to main section 218 a. Beak section 218 c of distal portion 217 a of insulative housing 216 is disposed distally of tissue-contacting plate 214 and extends to or beyond tissue-contacting plate 214. Beak section 218 c inhibits tissue from entering the area between jaw members 210, 220 of end effector assembly 200 when end effector assembly 200 is disposed in the closed position and utilized for blunt dissection.

Turning to FIG. 2 , one method of securing seal plate 214 atop the spacer and jaw support 235 is shown. More particularly, during an initial manufacturing step, the seal plate 214 is positioned atop the spacer 233 which rests atop the jaw support 235. The seal plate 214 includes a tissue engaging surface 214 a and downwardly extending flange 214 b that extends at least partially along the spacer 233 once seated atop the spacer 233. During the initial manufacturing step and once seal plate 214 is seated atop spacer 233, the flange 214 b is spaced from spacer 233. Insulative housing 216 is then overmolded over the spacer 233, jaw support 235 and a portion of the flange 214 b of seal plate 214 to capture and secure the seal plate 214 atop the spacer 233 and jaw support 235. During the overmolding process, the flange 214 b of the seal plate 214 is deformed (e.g., bent) against an outer peripheral surface 233 a of the spacer 233 to secure the sealing plate 214 thereto (See phantom in FIG. 2 ). In embodiments, spacer 233 may include a geometry (dovetail, angled face, etc.) to mechanically engage the flange 214 b.

FIGS. 3A-3B illustrate another method of securing a seal plate 314 atop an insulative spacer 316 and jaw support 371. More particularly, during an initial manufacturing step, the seal plate 314 is held in spaced relation relative to the jaw support 371 by retention posts or cores 381 a and 381 b and placed within a mold that includes top and bottom halves 390 a, 390 b. An insulative spacer 316 is then overmolded to fill the space between the seal plate 314 and the jaw support 371 to capture and secure the seal plate 314 atop the jaw support 371 in a single step molding process. In embodiments, the seal plate 314 may include a geometry (dovetail, angled face, etc.) to mechanically engage the insulative spacer 316. In embodiments, the retention posts or cores 381 a and 381 b are removed during the overmold process.

FIGS. 4A-4B illustrate another method of securing a seal plate 414 atop an insulative spacer and jaw support 471. More particularly, during an initial manufacturing step, the seal plate 414 is held in spaced relation relative to the jaw support 471 by a mesh-like material 481. A first overmolding process fills the mesh-like material 481 (or other materials using holes and counterbores) and secures seal plate 414 in spaced relation atop the jaw support 471. An insulative housing 416 is then overmolded to surround the jaw support 471 and secure the seal plate 414 atop the jaw support 471. In embodiments, the seal plate 314 may include a geometry (dovetail, angled face, etc.) to mechanically engage the insulative housing 416. The mesh-like material 481 may be metal and welded, bonded or crimped to the underside of the seal plate 414. The mesh-like material 481 may also be a polymer material or the same material as the insulative housing 416.

FIG. 5 illustrates yet another method of securing a seal plate 514 atop an insulative spacer 575 and jaw support 571. More particularly, during an initial manufacturing step, the seal plate 514 is registered in spaced relation relative to the jaw support 571 prior to overmolding. A series of mechanical interfaces (flanges, scallops, dove-tails, tabs, etc.) 514 a, 514 b are aligned in registry with a corresponding series of mechanical interfaces (grooves, slots, depressions) 571 a, 571 b defined within the jaw support 571. An insulative spacer 575 is then overmolded to fill the space between the seal plate 514 and the jaw support 571 to capture and secure the seal plate 514 atop the jaw support 571 in a single step molding process.

FIGS. 6A-6C illustrates yet another method of securing a seal plate 614 atop an insulative spacer 691 and jaw support 671. The jaw support 671 may be metallic. More particularly, during an initial manufacturing step, the seal plate 614, insulative spacer 691 and jaw support 671 are aligned in registry atop one another. One or more scallops or flanges 614 a are configured to depend from seal plate 614 along a peripheral edge thereof. A corresponding cavity 692 is defined within a flange 691 a of insulative spacer 691 and is dimensioned to seat flange 614 a therein. Flange 691 a is, in turn, dimensioned to seat within a corresponding cavity 671 a defined within jaw support 671. During assembly, flanges 614 a, 691 a and cavity 671 a are aligned and assembled atop one another (See FIGS. 6B and 6A). One or more rivets or screws 687 a, 687 b may be utilized to secure the seal plate 614 atop the insulative spacer 691 and jaw support 671 after assembly. Flange 614 a may include one or more holes 695 a, 695 b (See FIG. 6B) defined therein to facilitate this purpose. An electrical connection (e.g., wire 310 a) may be fed from the seal plate 614, through the insulative spacer 691 and jaw structure 671 and back to an electrical source during the assembly process (See FIG. 6B). Once the seal plate 614, insulative spacer 691 and jaw support 671 are assembled, an outer jaw housing 616 may be overmolded (or otherwise secured) to surround the jaw support 671, insulative spacer 691 and seal plate 614 (or a portion thereof) in a molding process. The outer jaw housing 616 may be made from an insulative material. As can be appreciated, when utilizing rivets or screws, additional overmolding steps may be eliminated.

In embodiments, the seal plate 614 may include a peripheral edge 617 disposed therearound that is dimensioned to mechanically engage (snap-fit, friction fit, compression fit, etc.) a corresponding lip 619 of the jaw housing 616 to secure the jaw housing 616 to the seal plate 614. If the jaw housing 616 is overmolded to surround the seal plate 614, insulative spacer 691 and jaw support 671, the peripheral edge 617 of the seal plate 614 may be dimensioned to mechanically engages the jaw housing 616 during the overnolding process to secure the jaw housing 616 to the seal plate 614.

The various embodiments disclosed herein may also be configured to work with robotic surgical systems and what is commonly referred to as “Telesurgery.” Such systems employ various robotic elements to assist the surgeon and allow remote operation (or partial remote operation) of surgical instrumentation. Various robotic arms, gears, cams, pulleys, electric and mechanical motors, etc. may be employed for this purpose and may be designed with a robotic surgical system to assist the surgeon during the course of an operation or treatment. Such robotic systems may include remotely steerable systems, automatically flexible surgical systems, remotely flexible surgical systems, remotely articulating surgical systems, wireless surgical systems, modular or selectively configurable remotely operated surgical systems, etc.

The robotic surgical systems may be employed with one or more consoles that are next to the operating theater or located in a remote location. In this instance, one team of surgeons or nurses may prep the patient for surgery and configure the robotic surgical system with one or more of the instruments disclosed herein while another surgeon (or group of surgeons) remotely control the instruments via the robotic surgical system. As can be appreciated, a highly skilled surgeon may perform multiple operations in multiple locations without leaving his/her remote console which can be both economically advantageous and a benefit to the patient or a series of patients.

The robotic arms of the surgical system are typically coupled to a pair of master handles by a controller. The handles can be moved by the surgeon to produce a corresponding movement of the working ends of any type of surgical instrument (e.g., end effectors, graspers, knifes, scissors, etc.) which may complement the use of one or more of the embodiments described herein. The movement of the master handles may be scaled so that the working ends have a corresponding movement that is different, smaller or larger, than the movement performed by the operating hands of the surgeon. The scale factor or gearing ratio may be adjustable so that the operator can control the resolution of the working ends of the surgical instrument(s).

The master handles may include various sensors to provide feedback to the surgeon relating to various tissue parameters or conditions, e.g., tissue resistance due to manipulation, cutting or otherwise treating, pressure by the instrument onto the tissue, tissue temperature, tissue impedance, etc. As can be appreciated, such sensors provide the surgeon with enhanced tactile feedback simulating actual operating conditions. The master handles may also include a variety of different actuators for delicate tissue manipulation or treatment further enhancing the surgeon's ability to mimic actual operating conditions.

From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the same. While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

1-17. (canceled)
 18. A jaw member of an electrosurgical forceps, comprising: an electrically conductive tissue-contacting plate including a peripheral edge and a flange extending vertically relative to the rest of the peripheral edge of the tissue-contacting plate; an insulative spacer including a peripheral edge and a flange extending vertically from the peripheral edge of the insulative spacer, the flange of the insulative spacer forming a cavity vertically aligned with the flange of the tissue-contacting plate, wherein the flange of the tissue-contacting plate is configured for receipt within the cavity of the insulative spacer; a jaw support including a peripheral edge forming a cavity vertically aligned with the flange of the insulative spacer and the flange of the tissue-contacting plate, wherein the flange of the insulative spacer is configured for receipt within the cavity of the jaw support; and a jaw housing surrounding the jaw support, the insulative spacer, and at least a portion of the tissue-contacting plate.
 19. The jaw member according to claim 18, wherein the flange of the insulative spacer extends vertically relative to the rest of the peripheral edge of the insulative spacer.
 20. The jaw member according to claim 18, wherein the cavity of the jaw support is recessed relative to the rest of the peripheral edge of the jaw support.
 21. The jaw member according to claim 18, wherein the cavity formed by the flange of the insulative spacer is recessed relative to the rest of the peripheral edge of the insulative spacer.
 22. The jaw member according to claim 18, further comprising an electrical lead coupled to the tissue-contacting plate and extending through the insulative spacer for coupling to an electrosurgical energy source.
 23. The jaw member according to claim 18, wherein the jaw housing is overmolded onto the jaw support, the insulative spacer, and at least a portion of the tissue-contacting plate.
 24. The jaw member according to claim 18, wherein at least a portion of the peripheral edge of the tissue-contacting plate mechanically engages a lip formed by the jaw housing to secure the tissue-contacting plate to the jaw housing.
 25. The jaw member according to claim 18, wherein the jaw housing is formed of an insulative material.
 26. The jaw member according to claim 18, wherein the jaw support is formed of a metal material.
 27. The jaw member according to claim 18, wherein the tissue-contacting plate is secured to the jaw housing by a rivet.
 28. The jaw member according to claim 18, wherein the tissue-contacting plate is secured to the jaw housing by a screw.
 29. A jaw member of an electrosurgical forceps, comprising: an electrically conductive tissue-contacting plate including a peripheral edge and a flange extending vertically relative to the rest of the peripheral edge of the tissue-contacting plate; an insulative spacer aligned in vertical registration with the tissue-contacting plate, the insulative spacer including a peripheral edge and a flange extending vertically from the peripheral edge of the insulative spacer, the flange of the insulative spacer forming a cavity vertically aligned with the flange of the tissue-contacting plate, wherein the flange of the tissue-contacting plate is configured for receipt within the cavity of the insulative spacer; and a jaw support aligned in vertical registration with the insulative spacer, the jaw support including a peripheral edge forming a cavity vertically aligned with the flange of the insulative spacer, wherein the flange of the insulative spacer is configured for receipt within the cavity of the jaw support.
 30. The jaw member according to claim 29, further comprising a jaw housing surrounding the jaw support, the insulative spacer, and at least a portion of the tissue-contacting plate.
 31. The jaw member according to claim 30, wherein the jaw housing is formed of an insulative material.
 32. The jaw member according to claim 30, wherein at least a portion of the peripheral edge of the tissue-contacting plate mechanically engages a lip formed by the jaw housing to secure the tissue-contacting plate to the jaw housing.
 33. The jaw member according to claim 29, wherein the flange of the insulative spacer extends vertically relative to the rest of the peripheral edge of the insulative spacer.
 34. The jaw member according to claim 29, wherein the cavity of the jaw support is recessed relative to the rest of the peripheral edge of the jaw support.
 35. The jaw member according to claim 29, wherein the cavity formed by the flange of the insulative spacer is recessed relative to the rest of the peripheral edge of the insulative spacer.
 36. The jaw member according to claim 29, wherein the jaw support is formed of a metal material.
 37. A jaw member of an electrosurgical forceps, comprising: an electrically conductive tissue-contacting plate including a peripheral edge and a flange extending vertically from the peripheral edge of the tissue-contacting plate; an insulative spacer including a peripheral edge and a flange extending vertically from the peripheral edge of the insulative spacer, the flange of the insulative spacer forming a cavity vertically aligned with the flange of the tissue-contacting plate, wherein the flange of the tissue-contacting plate is configured for receipt within the cavity of the insulative spacer; and a jaw support including a peripheral edge forming a cavity that is recessed relative to the rest of the peripheral edge of the jaw support, the cavity vertically aligned with the flange of the insulative spacer and the flange of the tissue-contacting plate, wherein the flange of the insulative spacer is configured for receipt within the cavity of the jaw support. 